Continuous forms envelope converter system

ABSTRACT

A continuous forms press converts a roll of envelope paper into a continuous envelope form having a pair of longitudinal score lines spaced inwardly from the sides of the strip to provide side margins, a longitudinal row of pinfeed holes in each of the side margins, a plurality of successive integral envelope blank sections, a first transverse line of weakness on each of the envelope blank sections constituting a first fold line between a bottom sheet portion and a top sheet portion, a second transverse line of weakness on each of the envelope blank sections constituting a second fold line between the top sheet portion and a closure flap portion, and adhesive coatings on the closure flap and on the top sheet portion adjacent the side margins. Indicia are imprinted on each of the envelope blank sections signifying the relative position of the pinfeed holes with the leading edge of the envelope blank section. The continuous envelope form is fan folded along the first fold line of each envelope blank section to form a zig-zag folded stack suitable for feeding into a computer print-out device or an automatic typewriter where the envelope blank sections are automatically addressed in succession with addresses contained in a tape or punch card memory. The continuous form is again fan folded along the first fold line into a zig-zag stack and fed into a continuous forms envelope converter in which the continuous form is separated into separate envelop blanks and simultaneously portions of the side margins are died out, leaving side flaps integral with the bottom sheet portion. The converter folds over the side flaps, folds a top sheet portion of each blank over a bottom sheet portion thereof along the first fold line, activates the adhesive coatings adjacent the side margins of the top sheet portion for securing the side flaps thereto, and folds the closure flap portion over the bottom sheet portions. In order to facilitate proper alignment of a continuous envelope form with the feed pins of the envelope converter, index indicia corresponding to the indicia on the envelope blank section and a fold line index mark are provided on the converter. In addition, blocking means are provided for diverting a leading partial envelope blank section after it is separated from the strip. The converter is adjustable to accommodate continuous forms of different widths to provide envelopes of different lengths.

United States Patent Wilson 1 CONTINUOUS FORMS ENVELOPE CONVERTER SYSTEM [72] Inventor: Paul O. Wilson, Sevema Park, Md.

[73] Assignee: Baltimore Business Forms, Inc., Baltimore, Md.

[22] Filed: Jan. 13, 1971 [21] Appl.No.: 106,221

[52] US. Cl. ..93/63 R, 93/36 A, 93/36 MM, 93/58.3, 93/58.4, 93/62 [51] Int. Cl. ..B3lb l/08, B3lb l/16, B3lb 1/62 [58] Field of Search ..93/36 A, 36 MM, 58.3, 58.4, 93/61 A, 62, 63 R Primary Examiner-Wayne A. Morse, Jr. Attorney-Raphael Semmes 57 ABSTRACT A continuous forms press converts a roll of envelope paper into a continuous envelope form having a pair of longitudinal score lines spaced inwardly from the sides of the strip to provide side margins, a longitudinal row of pin feed holes in each of the side margins, a plurality of successive integral envelope blank sec- [151 3,683,756 [45] Aug. 15,1972

tions, a first transverse line of weakness on each of the envelope blank sections constituting a first fold line between a bottom sheet portion and a top sheet portion, a second transverse line of weakness on each of the envelope blank sections constituting a second fold line between the top sheet portion and a closure flap portion, and adhesive coatings on the closure flap and on the top sheet portion adjacent the side margins. Indicia are imprinted on each of the envelope blank sections signifying the relative position of the pinfeed holes with the leading edge of the envelope blank section. The continuous envelope form is fan folded along the first fold line of each envelope blank section to form a zig-zag folded stack suitable for feeding into a computer print-out device or an automatic typewriter where the envelope blank sections are automatically addressed in succession with addresses contained in a tape or punch card memory. The continuous form is again fan folded along the first fold line into a zig-zag stack and fed into a continuous forms envelope converter in which the continuous form is separated into separate envelop blanks and simultaneously portions of the side margins are died out, leaving side flaps integral with the bottom sheet portion. The converter folds over the side flaps, folds a top sheet portion of each blank over a bottom sheet portion thereof along the first fold line, activates the adhesive coatings adjacent the side margins of the top sheet portion for securing the side flaps thereto, and folds the closure flap portion over the bottom sheet portions. In order to facilitate proper alignment of a continuous envelope form with the feed pins of the envelope converter, index indicia corresponding to the indicia on the envelope blank section and a fold line index mark are provided on the converter. In addition, blocking means are provided for diverting a leading partial envelope blank section after it is separated from the strip. The converter is adjustable to accommodate continuous forms of different widths to provide envelopes of different lengths.

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mvsmon PAUL O.W|LSON VON A [TURN ET CONTINUOUS FORMS ENVELOPE CONVERTER SYSTEM BACKGROUND OF THE INVENTION addressed and which is thereafter converted into stanl0 dard envelopes.

It is frequently necessary to mail envelopes stuffed with form letters, advertising material, circulars, or the like to a large number of addresses. Since. the ad dressing of the envelopes manually from a mailing list is very time consuming, it has become the practice to employ automatic business machines within the memory of which the mailing list is stored for automatically preparing addressing labels for application to the envelopes. However, this practice requires that the labels be secured to the envelopes in an additional operation. It has also been suggested that addressing machines be employed having pre-addressed plates which may be employed for printing in sequence directly upon the envelopes, but systems of this character require a great deal of storage space for the addressing plates and require special machinery for making the plates.

It is therefore desirable to provide a system in which envelopes may be addressed directly from automatic computerized printers or typewriters which are programmed to print out addresses from a computer memory, and there have been a number of suggestions for addressing envelopes in this way. For example, it has been proposed that previously formed envelopes be adhesively secured to a continuous carrier strip of computer paper having rolls of pinfeed holes adjacent its side margins so that it might be easily fed through automatic computerized printing equipment. However, this system requires that the envelopes be secured to and detached from the carrier strip which is then discarded. It has also been suggested that addresses be printed directly upon a continuous form which is provided with pinfeed holes to facilitate pin feeding into automatic printing equipment and which is converted into envelopes by laminating it to a second continuous strip. The resulting envelopes are unconventional, different from the style of envelope customarily used in business practice, and are not adaptable for subsequent automatic stuffing and sealing operations.

The foregoing drawbacks of prior art equipment were overcome in the envelope converter system disclosed in my prior application, Ser. No. 751,467, filed Aug. 9, 1968, now U.S. Pat. No. 3,552,282, for Continuous Forms Envelope Converter System. This prior application discloses a system for converting a continuous strip of paper into separate addressed envelopes. The system includes press means for providing perforated lines on the strip transversely of the strip to divide the strip into a plurality of envelope blanks, a pair of score lines transversely of 'each blank to provide a first main fold line between a bottom sheet and a top sheet and a second fold line between the top sheet and a closure flap, a pair of longitudinal lines spaced inwardly from the sides of the strip to provide side margins, the longitudinal lines being score lines adjacent the bottom sheets to provide side flaps integral with the bottom sheets and perforated lines adjacent the top sheets to provide side trim zones, and a row of pinfeed holes within each of the side margins. The press includes adhesive coater means for providing adhesive coatings on the closure flap and adjacent to the side margins of the top sheet. The strip is folded into a continuous zig-zag folded stack suitable for feeding into automatic computerized printing equipment, the folds being effected along the perforated lines corresponding to the leading edge of each envelope blank. After the strip is pre-addressed in the automatic printing equipment, it is again folded into a zig-zag folded stack along the same fold lines and fed into a continuous forms envelope converter. This converter includes means for intermittently feeding the strip to bring the transverse perforated lines beneath a cutter knife which is synchronized with the intermittent feed to separate the strip into envelope blanks. The blanks are then conveyed past side trimmers in the form of rollers engaging the side margins, which remove the side trim zones by separating them along the longitudinal perforated line leaving side flaps integral with the bottom sheet. The blanks are conveyed past side flap folders positioned in the path of the side flaps for folding the side flaps over the bottom sheet. The envelope blanks are then fed into means for folding the top sheet over the bottom sheet and are conveyed past heaters which activate the adhesive coatings on the top sheet to seal the side flaps to the top sheet.

Although the system disclosed in my prior application has fulfilled the objective of producing automatically pre-addressed envelopes of conventional format, it has been found that this system is subject to a number of limitations in practice. For example, the envelope converter apparatus of my prior application is designed to receive a continuous envelope form having a fixed predetermined width and to produce envelopes having a fixed predetermined length only. If envelopes of a different length are desired. Or if the continuous envelope form is provided in a different width due to the requirements of the automated address printing equipment, it is necessary to provide a separate machine engineered to accept forms of the new width. The envelope converter of my prior application produces envelopes with the closure flap open. It has been found, however, that it is more advantageous to provide the envelopes with the closure flaps folded closed. Conventional automatic inserting equipment ordinarily require the envelopes be provided with the closure flaps folded closed and are provided with means to open the envelopes prior to inserting. When the closure flaps are closed, the flap glue is not exposed to the atmosphere, avoiding curling of the envelopes which would cause difficulties in the inserters. Because the flap is not exposed, it is protected from tearing and mutilation.

The system as disclosed in my prior application employs a continuous envelope form in which transverse perforated lines are employed at the ends of each envelope blank of the strip, and the form is folded along these perforated lines to form a zig-zag folded stack. A vertically reciprocating cutter knife is provided for separating the envelope blanks from the strip, and it is necessary that the knife engage the strip accurately along these transverse perforated lines.

The side trim removal rollers of my prior application are positioned at a point following the cutter knife and are effective after the blanks are separated from the strip, These rollers strip off the side trim by pulling it free along the longitudinal perforated lines. However, it has beenfound in practice that the side trim is not uniformly separated from the blanks. When the blanks are guided into the rollers, one side trim frequently breaks off before the other, causing the blank to enter the side folders with a crooked orientation. In addition, the weak perforations frequently cause separation of the side trim when the strip is being fed through the computerized printing equipment creating problems with the operation of that equipment.

The envelope converter apparatus of my prior application employs intermittent feed means for feeding the strip from the zigzag folded stack. The feed means includes a reciprocating rack, a slip clutch, a brake, and detent means for preventing reverse movement of the pinfeed belts upon reverse reciprocation of the rack. However, slippage in this intermittent drive system has caused timing errors which were avoided only by the adoption of a complex electrical system (not shown in my prior application).

SUMMARY OF THE INVENTION It is accordingly the principal object of the invention to provide an improved system for automatically addressing and forming envelopes for large scale mailings.

It is also an object of the invention to provide an improved envelope addressing system which provides addressed envelopes quickly and inexpensively, which eliminates costly addressing equipment, and which is substantially fully automated.

More specifically, it is an object of the invention to provide an improved envelope forming system which makes use of an improved continuous envelope form adapted to be fed through automatic computerized printing equipment to be pre-addressed therein and which converts the continuous form into envelopes of standard format.

Another object of the invention is the provision of an improved continuous envelope form specially prepared for feeding through automatic computerized printing equipment and for conversion into envelopes of standard format.

An additional object of the invention is the provision of an improved continuous forms envelope converter for converting a continuous envelope form, which has been pre-addressed in computerized printing equipment, into standard pre-addressed envelopes.

It is a further object of the invention to provide an improved continuous form envelope converter for converting a continuous envelope form of the aforementioned character into envelopes by separating it into individual envelope blank sections, dieing out excess material from the side margins thereof, folding side flaps, folding the blank about a main fold line, sealing the side flaps, and folding over a closure flap.

An additional object involves the provision of an envelope converter of the aforementioned character which is adjustable to receive continuous envelope forms of different widths and for producing completed envelopes of different lengths.

Yet another object involves the provision of an improved envelope converter having improved means for folding the closure flap.

Still another object is directed to the provision of an improved continuous envelope fonn having a plurality of integral envelope blank sections and characterized by the absence of a perforated line at the boundary between adjacent envelope blank sections. A related object is the provision of an improved envelope converter which includes knife means for separating the envelope blank sections at their trailing edge.

A further object of the invention relates to the provision of improved means for separating side trim from a continuous envelope form. More specifically, it is an object of the invention to provide die means operating simultaneously with the knife means for dieing out portions of the side margins of the continuous envelope form leaving side flaps integral with bottom sheet portions thereof. A related object is the provision of means for deflecting the side trim to a waste receptacle.

Another object relates to the provision of an improved carn drive for the knife head which vertically reciprocates to separate the continuous envelope form into separate envelope blank sections.

Still another object pertains to the provision of an envelope converter with improved intermittent feed means.

In order to accommodate conventional computerized print-out equipment it is necessary to space the pinfeed holes of the continuous envelope form at a spacing which is standard for such equipment. However, due to the standard height of business envelopes, it is not possible to position the pinfeed holes of each envelope blank section of the continuous envelope form the same distance from the leading edge of the section. It is accordingly necessary to adjust for this different spacing; otherwise, envelope blank sections will be engaged by the knife means at different positions,thereby resulting in envelopes having different dimensions. It is accordingly an object of the invention to provide indicia means for facilitating the feeding of a continuous envelope form into the continuous envelope converter in a manner accurately positioning the leading edge of each blank section with respect to the knife means.

Due to the fact that the continuous envelope form of the present invention is fan folded along the first fold line between the ,top sheet portion and the bottom sheet portion of each envelope blank section, the leading envelope blank section of each zig-zag folded stack is a partial envelope blank section. Since this partial section cannot be converted into an envelope by the envelope converter of the present invention, it is necessary to dispose of it. Accordingly, it is an object of the invention to provide means for diverting the leading partial envelope blank section to a waste receptacle after it is separated from the continuous envelope form.

Briefly, the invention contemplates a system and method for converting a continuous strip of paper into separate addressed envelopes. The system includes press means for providing the continuous strip with a pair of longitudinal score lines spaced inwardly from the sides of the strip to provide side margins, a longitudinal row of pinfeed holes in each of the side margins, a plurality of successive integral envelope blank sections, a first transverse line of weakness on each of the envelope blank sections constituting a first fold line between a bottom sheet portion and top sheet portion, a second transverse line of weakness on each of the envelope blank sections constituting a second fold line between the top sheet portion and closure flap portion, the closure flap portion having an edge corresponding to the leading edge of the envelope blank section contiguous with the trailing edge of an adjacent envelope blank section, and adhesive coatings on one side of the strip on the closure flap portion and on the top sheet portion adjacent the side margins. The press means also provides indicia on successive envelope blank sections signifying the relative position of the pinfeed holes thereon with respect to the leading edge thereof. The strip is fan folded along the first fold line to form a zig-zag folded stack which is received in printer means for successively printing addresses on one of the top and bottom sheet portions of successive envelope blank sections and for refolding the continuous strip along the first fold line as an addressed zig-zag folded stack. A continuous forms envelope converter according to the invention includes a pair of intermittent feed means for engaging respectively the rows of pinfeed holes in each side margin of the continuous envelope form for feeding the form from the zig-zag folded stack. The intermittent feedmeans includes a partial gear having teeth only part way therearound and provided with a cam cooperating with a cam follower on an interrnitting gear driven by the partial gear to prevent teeth clash. The converter includes knife means for separating the envelope blank sections from the strip at the trailing edge of each envelope blank section, and a pair of side die means for dieing out the portions of the side margins adjacent the top sheet portion and the closure flap portion, leaving side flaps integral with the bottom sheet portion. The die means is driven to operate simultaneously with the knife means separating the blank sections from the strip. As the knife means separates the blank from the strip, drive rollers become effective to convey the blank to a pair of side flap 'fold means for folding the respective side flaps over the bottom sheet portion and into engagement with adhesive coatings adjacent the side margins of the top sheet portion. Means are provided for folding the top sheet portion over the bottom sheet portion along the first fold line and directing the blank along a downward path past heater means for activating the adhesive coatings on the top sheet portion for securing the side flaps thereto. The blanks are received by means for folding the closure flap portion over the bottom sheet portion.

In order to facilitate adjustment of the envelope converter for receiving continuous envelope forms of different predetermined widths and for producing completed envelopes of different predetermined lengths, the converter includes lateral adjustment means for adjusting the spacing between the pair of intermittent feeding means, the pair of die means, the pair of side flap fold means, and the pair of heater means. It is contemplated by the invention that the adjustment means include first means for simultaneously adjusting the spacing between the pair of intermittent feed means and the pair of die means and second means for simultaneously adjusting the spacing between the pair of side flap fold means and the pair of heater means.

In order to divert the leading partial envelope blank section of the continuous envelope form to a waste receptacle, it is contemplated by the invention that the leading edge of the strip be fed into the envelope converter while the intermittent feed] means, knife means, and side die means are hand driven toward a blocking structure which is placed in position to block the passage of the leading partial envelope blank section and direct it to the waste receptacle. This blocking structure is then returned to a position no longer blocking passage of the full envelope blank sections to the side flap fold means. The invention also contemplates a method of inserting the leading end of the continuous envelope form into the envelope converter by adjusting the position of a feed pin into alignment with an index indicia on the converter corresponding to indicia on the envelope blank sections signifying the spacing of the pinfeed holes on the respective envelope blank section from the leading edge thereof and engaging the first full envelope blank section with the feed pins of the intermittent feed means with the first fold line of the leading full envelope blank section in alignment with an index mark on the envelope converter. The index indicia and the index mark are so positioned that the leading edge of the first full envelope blank section will then be properly positioned beneath the knife means.

The foregoing and other objects, advantages, and features of the invention and the manner in which the same are accomplished will become more readily ap parent upon consideration of the following detailed description of the invention when taken in conjunction with the accompanying drawings, which illustrate preferred and exemplary embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic diagram of a continuous forms envelope converter system of the invention;

FIG. 2 is a partial plan view of a continuous envelope form used in the system of the invention;

FIG. 3 is a perspective view of a completed envelope of the invention;

FIG. 3A is a partial sectional view along line 3A-3A of FIG. 3;

FIG. 4 is a plan view of a continuous envelope forms converter of the invention with parts broken away;

FIG. 4A is a schematic plan view of the converter with parts omitted to show the lateral adjustment means of the invention;

FIG. 5 is a partial schematic side elevation view, partly in section, of the continuous forms envelope converter of FIG. 4;

FIG. 6 is a partial schematic side elevation view, partly in section, of the continuous forms envelope converter of FIG. 4;

FIG. 7 is a partial perspective view of one of the intermittent feed means of the invention;

FIG. 8 is a schematic partial plan view of the intermittent feed means of the invention;

FIG. 9 is a schematic diagram of intermittent gear means of the invention in a first position;

FIG. 10 is a schematic diagram of intermittent gear means of the invention in a second position;

FIG. 11 is a schematic diagram of intermittent gear means of the invention in a third position;

FIG. 12 is a schematic diagram of intermittent gear means of the invention in a fourth position;

FIG. 13 is a partial perspective view of one of the side die means of the invention;

FIG. 14 is a partial plan view of the scrap remover means of the invention, partly in section;

FIG. 15 is a sectional view along line 1515 of FIG. 14;

FIG. 16 is a sectional view along line 16-l6 of FIG. 14;

FIG. 17 is a schematic section view along lines 17-- 17 of FIG. 5 with parts broken away; and

FIG. 18 is a partial schematic perspective view of the converter apparatus of FIG. 4.

DETAILED DESCRIPTION OF THE DRAWINGS Referring to FIG. 1, it will be seen that a continuous forms envelope converter system of the invention includes a rotary forms press 20 which converts a strip 22 of envelope paper stock from a roll 24 into a continuous envelope form 26, shown in more detail in FIG. 2, fan folded into a continuous zig-zag folded stack 28. Since rotary forms press 20 comprises conventional apparatus, it will not be described in detail herein. However, it is to be understood that this press applies score lines to the strip 22, punches a pair of rows of pinfeed holes therein along each of the edges, cuts perforations and diagonal cuts therein, applies adhesive coatings thereto, and prints printed matter thereon. Turning to FIG. 2, it will be seen that the continuous envelope form 26 includes a pair of longitudinal lines of weakness or score lines 30 and 32 spaced at short distance inwardly from the respective side edges 34 and 36 of form 26 to define a pair of side margins 38 and 40. A longitudinal row of pinfeed holes 42 is provided in side margin 38, while a similar longitudinal row of pinfeed holes 44 is provided in side margin 40. The continuous envelope form 26 is provided with a plurality of successive full envelope blank sections 46 each of which is provided with a transverse line of weakness of perforated line 48 extending from side edge to side edge of the strip and constituting a first fold line between a bottom sheet portion 50 and a top sheet portion 52 of full envelope blank section 46. Each full envelope blank section is also provided with a transverse line of weakness or perforated line 54 extending between score line 30 and score line 32 and constituting a second fold line between the top sheet portion 52 and a closure flap portion 56. The leading edge of closure flap portions 56 corresponds to the leading edge of each envelope blank section 46 and is contiguous with the trailing edge of the next leading envelope blank section. While the leading and trailing edges of the envelope blank sections are not marked, a line of division 58 between successive envelope blank sections is shown in FIG. 2 and will, as will be explained more fully hereinafter, be the line along which each envelope blank section is separated along its trailing edge from the continuous envelope form. It will be observed that the line of division 58 does not extend perpendicularly from the side edges but extends slightly forwardly of the line of perpendicularity so that the closure flap portion will have a point 60 representing the apex of a quarter inch throat to facilitate engagement with automatic inserter machinery. The side edges of the closure flap portions 56 are defined by a pair of diagonal slashes 62 and 64 extending inwardly from the points of intersection between second fold line 54 and longitudinal score lines 30 and 32, respectively, and the line of division 58.

As will be explained more fully hereinafter, side trim zones 66 and 68 will be separated from the envelope blank sections 46. Each of these side trim zones will incorporate portions of the side margins 38 and 40, respectively, extending from the first fold line 48 to the line of division 58 and incorporating the portion of the form between diagonal slashes 62 and 64 and side edges 34 and 36, respectively.

After side trim zones 66 and 68 are removed, the portions of the side margins contiguous with bottom sheet portion 50 will remain. These portions will serve as side flaps 67 and 69 respectively of the completed envelope. In the continuous envelope form 26 as seen in FIG. 2, the top or printed side of the form is visible and various printing material, such as return addresses and advertising matter (not shown), may be printed thereon as desired. In addition, indicia 70, 72 and 74 are printed on successive envelope blank sectionsand will have the purpose of facilitating proper insertion of the continuous envelope form into envelope converter apparatus, as will be described in more detail hereinafter.

As seen in phantom line in FIG. 2, adhesive coatings are provided on the opposite side of form 26. A first adhesive coating 76 is provided on the closure flap portions 56 adjacent the leading edge thereof, and a pair of adhesive coatings 78 and 80 are provided on the top sheet portions 52 adjacent the longitudinal score lines 30 and 32, respectively. These adhesive coatings are of a type which is heat activatable so that when the envelope form is subjected to heat and pressure, as will be explained more fully below, the adhesive coatings will become activated.

As will be noted from FIG. 2, the envelope blank section 82 between the leading line of division 58 and the leading end 84 of form 26 is much shorter than full envelope blank sections 46 constituting the remainder of form 26. In point of fact, the distance between leading end 84 and the leading line of division 58 is equal to the distance between the first fold line and trailing edge of each of the full envelope blank sections 46. For this reason, envelope blank section 82 will be referred to hereinafter as a partial envelope blank section.

Since it is intended that the continuous envelope form 46 will be fed through automatic computerized addressing equipment, it is desirable that the pinfeed holes of the two longitudinal rows of pinfeed holes be spaced in accordance with the standards of conventional computer print-out paper. To this end, the pinfeed holes in each row are spaced one-half inch apart, center-to-center. This would appear to require that the length of each envelope blank section be such that the pinfeed holes are at the same relative distance from the leading edge thereof on each envelope blank section, but this would result in envelopes having an unconventional dimension, heightwise. This difficulty is avoided, however, in accordance with the present invention, by orivudubg the envelope blank sections in recurrent series of n envelope blank sections each of which has a different relative position of pinfeed hole to leading edge. The total length of the recurrent series is selected so that this relative position of pinfeed hole to leading edge will repeat every n envelope blank sections. Thus, in one example adopted in a practical embodiment of the invention, the recurrent series includes three envelope blank sections. This enables the use of envelope blank sections having a total length longitudinally of the form of 9-56 inches with the total length of the recurrent series of three envelope blank sections being 28 inches. Since a ,6 inch spacing is adopted for the pinfeed holes, it will be readily apparent that the relative position of pinfeed holes to leading edge will repeat every three envelope blank sections and will be the same on each envelope blank section of a recurrent series as on the corresponding envelopeblank section in the other series on the form.

Each of the indicia 70,72 and 74, which, in the example given, are the letters G, R, and B, signify which of the relative positions a particular envelope blank section embodies. That is, the relative spacing of pinfeed holes on envelope blank sections marked by indicia G will be the same as the relative position on all other envelope blank sections marked G; the relative position of pinfeed holes to leading edge on all envelope blank sections marked R will be the same; and, likewise, the relative position of pinfeed hole to leading edge on all envelope blank sections marked B will be identical. As will be explained in more detail hereinafter, this information will be used when an envelope form 26 is fed into envelope converter apparatus to ensure that the envelope blank sections are separated at the proper line of division.

In order to provide envelope blank sections in the aforementioned recurrent series, rotary forms press may include a printing cylinder with a 28 inch circumference which will provide an entire series of three envelope blank sections. The rotary forms press will also include a pinfeed hole punching ring which has a circumference of 22 inches providing a pinfeed hole every one-half inch along the continuous form.

As mentioned above, the lines of division 58 corresponding to the trailing edge of each envelope blank section do not constitute fold lines. Accordingly, zigzag folded stack 28 is not formed by folding the continuous strip 26 along a fold line corresponding to an end of the envelope blank section as was the case in my prior application, Ser. No. 751,467. In accordance with the present invention, the continuous form 26 is fan folded along the first fold lines 48 of each of the envelope blank sections. After the form is thus folded into a zig-zag folded stack, it is transported to a computerized address printer 100. The printer will be a printout device of conventional computer equipment or a pin-fed automatic typewriter, which includes a memory in the form of pre-punched cards or magnetic tape containing address information, and which is programmed automatically to print the addresses stored in the memory on successive envelope blank sections 46 on either the top or bottom sheet portion thereof. Such equipment is readily adapted for quick and inexpensive correction or updating of the mailing list. After continuous form 26 is thus addressed, it is refolded into a zig-zag folded stack 28 along first fold lines 48. The continuous form will now comprise a plurality of envelope blank sections 46 each of which is pre-addressed with a particular address as determined by the computer or automatic address printer 100.

The continuous envelope form 26 will now be in condition for conversion into individual pre-addressed envelopes. This is accomplished in the continuous forms envelope converter 110. As shown in FIG. 1, envelope converter is of such size that it may be conveniently positioned upon a table 112. The addressed zig-zag folded stack 28 may be positioned at one end of table 112 so that continuous form 26 may be readily fed into envelope converter 110. As will be described in greater detail hereinafter, envelope converter 110 will separate the envelope blank sections 46 from continuous envelope form 26 and convert them into completed envelopes 114 which. are delivered from converter 110 to conveyor belt 116. After a supply of completed addressed envelopes 114 have accumulated in a stack 118, the stack may be transported to automatic inserting equipment which will serve to stuff the envelopes with the material to be mailed and which will subsequently seal the closure flaps of the envelopes for mailing.

Considering the continuous forms envelope converter 110 in greater'detail and referring initially to FIGS. 4, 4A, 5 and 7, it will be observed that continuous form 26 is fed into envelope converter 110 by means of a pair of intermittent pinfeed means only one of which is shown in FIG. 4. As seen in FIG. 4A, however, identical pinfeed means 120 are provided on both sides of the converter. With. particular reference to FIGS. 5 and 7, it will be seen that each of the pinfeed means is in the form of a continuous tractor belt 122 having a plurality of feed pins 124 projecting therefrom. The feed pins are spaced apart with the same spacing as the pinfeed holes 42 and 44 of continuous envelope form 26; thus, in the example given above, the spacing will be one-half inch, center-tocenter. As will be explained. in greater detail hereinafter, pinfeed holes 42 and 44 of continuous form 26 are engaged with the respective pinfeed means 120, which are driven in an intermittent fashion to advance form 26 to feed each envelope blank section successively into converter 110. After so advancing the form, intermittent feed means enters a dwell period to permit separation of the envelope blank sections from the continuous envelope form 26., as will be explained hereinafter.

With reference to FIGS. 4, 5, 6,. 9, 10, 11 and 12, the drive means for pinfeed means 120 will now be described. A motor 126 drives an overrunning clutch pulley 128 which is coupled by a drive belt 130 to a compound pulley 132 on a shaft 135. A timing belt drive pulley 134 on shaft 135 drives a timing belt 136 to drive a timing belt pulley 138 (FIG. 5) mounted on a shaft 140. A special partial gear 142 is mounted on shaft 140. As will be seen most clearly from FIGS. 9, 10, 11 and 12, gear 142 is provided with forty gear teeth 144 over one-half of its periphery. Gear 142 is made from an eighty tooth gear, one-half of the teeth of which are milled OK to form a smooth portion 146 extending about the other half thereof. Gear 142 is adapted to become engaged with an intermitting driven gear 148 having 40 teeth completely around its periphery. The manner in which gear 142 drives gear 148 in an intermittent fashion will be best understood 

1. A continuous forms envelope converter for receiving a continuous paper strip having a pair of longitudinal lines of weakness spaced inwardly from the sides of said strip to provide side margins, a longitudinal row of pinfeed holes in each of said side margins, a plurality of successive integral envelope blank sections, each of said envelope blank sections being provided with a first transverse line of weakness extending from one side edge of said strip to the other side of the strip and constituting a first fold line between a bottom sheet portion and a top sheet portion of said envelope blank section, each of said envelope blank section being provided with a second transverse line of weakness extending from one of said longitudinal lines of weakness to the other of said longitudinal lines of weakness and constituting a second fold line between said top sheet portion and a closure flap portion of said envelope blank section, said closure flap portion having an edge corresponding to the leading edge of said envelope blank section contiguous with the trailing edge of an adjacent envelope blank section, and adhesive coatings on said closure flap and adjacent to the side margins of said top sheet portion, said strip being fan folded to form a zig-zag folded stack, said converter comprising: a pair of intermittent feed means for engaging respectively said row of pinfeed holes in each side margin for feeding said strip from said zig-zag folded stack; a pair of die means for dieing out portions respectively of said side margins adjacent said top sheet portion and said closure flap portion, the portions of said side margins adjacent said bottom sheet portion then constituting side flaps integral with said bottom sheet portion; means for separating said envelope blank sections from said strip at said trailing edge of said envelope blank sections; a pair of side flap fold means for folding a respective side flap over said bottom sheet portion; means for folding said top sheet portion over said bottom sheet portion along said first fold line to bring said folded over side flaps into engagement with the adhesive coatings on said top shEet portion; a pair of heater means for activating respectively the adhesive coating on said top sheet portion; means for folding said closure flap portion over said bottom sheet portion; and adjustment means for adjusting the spacing between said pair of intermittent feed means, said pair of die means, said pair of side flap fold means, and said pair of heater means, whereby said converter may be adjusted to produce addressed envelopes of different lengths.
 2. A continuous forms envelope converter as recited in claim 1, wherein said adjustment means comprises first means for simultaneously adjusting the spacing between said pair of intermittent feed means and said pair of die means and second means for simultaneously adjusting the spacing between said pair of side flap fold means and said pair of heater means.
 3. A continuous forms envelope converter as recited in claim 1, wherein one of said intermittent feed means on one side is structurally tied to said die means on that side, the other of said pair of intermittent feed means on the other side is tied to said die means on the other side, bracket means joins one of said pair of heater means and one of said side fold means on the one side, and second bracket means joins the heater means and side flap fold means on the other side, said first means comprising a first screw member having an adjustment knob and being coupled to said die means on said one side and said die means on the other side so as to move said die means toward or away from each other and second means including a screw device having an adjusting knob engaged with said brackets on each side for moving said brackets toward or away from each other for simultaneously adjusting the spacing between said heater means and said side flap fold means.
 4. A continuous forms envelope converter for receiving a continuous paper strip having a pair of longitudinal lines of weakness spaced inwardly from the sides of said strip to provide side margins, a longitudinal row of pinfeed holes in each of said side margins, a plurality of successive integral envelope blank sections, each of said envelope blank sections being provided with a second transverse line of weakness extending from one of said longitudinal lines of weakness to the other of said longitudinal lines of weakness and constituting a second fold line between said top sheet portion and a closure flap portion of said envelope blank section, said closure flap portion having an edge corresponding to the leading edge of said envelope blank section contiguous with the trailing edge of an adjacent envelope blank section, and adhesive coatings on said closure flap and adjacent to the side margins of said top sheet portion, said strip being fan folded to form a zig-zag folded stack, said converter comprising: intermittent feed means for engaging said rows of pinfeed holes for feeding said strip from said zig-zag folded stack; die means for dieing out portions of said side margins adjacent said top sheet portion and said closure flap portion, the portions of said side margins adjacent said bottom sheet portion then constituting side flaps integral with said bottom sheet portion; knife means for cutting said strip along said trailing edges of said envelope blank sections for separating said envelope blank sections from said strip; side flap fold means for folding said side flaps over said bottom sheet portion; means for folding said top sheet portion over said bottom sheet portion along said first fold line to bring said folded over side flap portions into engagement with said adhesive coatings on said top sheet portion; heater means for activating the adhesive coatings on said top sheet portion; means for folding said closure flap portion over said bottom sheet portion; and drive means coupled to said intermittent feed means, to said knife means, and to said die means, said drive means driving said knife means and said die means for simultaneous operation when Said intermittent feed means is in a dwell period with said strip stationary beneath said knife means and die means.
 5. A continuous forms envelope converter as recited in claim 4, wherein said intermittent drive means comprises a first gear driven by said drive means, a portion of the circumference of said first gear being provided with gear teeth and the remainder of the circumference of said first gear being free of gear teeth, a second gear adapted to be driven by said first gear when engaged with the teeth of said first gear and to remain stationary in a dwell period when the portion of the first gear having no teeth moves past said second gear, a pinfeed tractor assembly driven by said second gear and having a plurality of pins adapted to engage with said pinfeed holes to move said strip into said envelope converter when said second gear is engaged with the teeth of said first gear and to hold said strip in a dwell period when said second gear is disengaged from the teeth of said first gear.
 6. A continuous forms envelope converter as recited in claim 5, wherein said first gear comprises a cam track and said second gear comprises a cam follower engageable with said cam track, said cam track being so positioned and shaped as to lift said gear teeth of said second gear from said gear teeth of said first gear at a point on said first gear where said gear teeth discontinue and to engage said gear teeth of said second gear to the gear teeth of said first gear at a point where the gear teeth of said first gear begin.
 7. A continuous forms envelope converter as recited in claim 4, wherein said knife means is mounted for vertical reciprocation into engagement with said continuous strip by means of an eccentric driven crank arm coupled to said drive means and wherein said die means is driven for vertical reciprocation into engagement with said strip simultaneously with the engagement of said strip by said knife means by means of a cam coupled to said drive means through a timing belt.
 8. A continuous forms envelope converter as recited in claim 7, further comprising finger means operated synchronously with said die means for downwardly deflecting the died out portions of said side margins to insure their separation from said strip.
 9. A continuous forms envelope converter as recited in claim 7 further comprising envelope blank section feed means having a driven roller and a pinch roller, said pinch roller being reciprocated downwardly with said knife means to engage the envelope blank section immediately after it is separated from said strip by said knife means to feed it to said side fold means, said pinch roller being biased out of engagement from said drive roller when said knife means reciprocates upwardly.
 10. A continuous forms envelope converter for receiving a continuous paper strip having a pair of longitudinal lines of weakness spaced inwardly from the sides of said strip to provide side margins, a longitudinal row of pinfeed holes in each of the said side margins, said pinfeed holes being spaced in accordance with the spacing of the pinfeed holes on conventional computer print-out paper, a plurality of successive integral envelope blank sections of such length along said strip as to conform, when converted into an envelope, to a conventional envelope width, said pinfeed holes on successive envelope blank sections being placed at different positions relative to the leading edge of the envelope blank section, said relative position of pinfeed holes to leading edge repeating every n envelope blank sections, where n is an integer greater than one, said strip having recurrent series of n envelope blank sections, each section of said series having pinfeed holes with the same relative position to leading edge as corresponding sections in each of the series, indicia on each of said envelope blank sections signifying the relative position of pinfeed holes to leading edge on that section, each of said envelope blank sections being provided wIth a first transverse line of weakness extending from one side edge of said strip to the other side edge of the strip a constituting a first fold line between a bottom sheet portion and a top sheet portion of said blank section, and each of said envelope blank sections being provided with a second transverse line of weakness extending from one of said longitudinal lines of weakness to the other of said longitudinal lines of weakness and constituting a second fold line between said top sheet portion and a closure flap portion of said envelope blank section, said closure flap portion having an edge corresponding to the leading edge of said envelope blank section contiguous with the trailing edge of an adjacent envelope blank section, said strip being fan folded along said first fold line of each envelope blank portion to form a zig-zag folded stack, said converter comprising: intermittent feed means including a plurality of successive feed pins for engaging said rows of pinfeed holes in said side margins for feeding said strip from said zig-zag folded stack; die means for dieing out portions of said side margins adjacent said top sheet portion and said closure flap portion, the portions of said side margins adjacent said bottom sheet portion then constituting side flaps integral with said bottom sheet portions; means for separating said envelope blank sections from said strip at said trailing edge of said envelope blank sections; side flap fold means for folding said side flaps over said bottom sheet portion; means for folding said top sheet portion over said bottom sheet portion along said first fold line; index means providing n index indicia adjacent said intermittent feed means corresponding to the indicia on each of said envelope blank sections of said recurrent series and a first fold line index mark adjacent said intermittent feed means; and manual feed means for advancing said feed pins of said intermittent feed means to bring one of said feed pins into alignment with the index indicia of said index means corresponding to the indicia on the leading full envelope section of said strip, said index indicia being so positioned that the leading edge of said leading full envelope blank section will be properly positioned relative to said means for separating said envelope blank sections when said feed pin and index indicia are so aligned and said first fold line of said leading full envelope blank section is algined with said index mark.
 11. A continuous forms envelope converter as recited in claim 10, wherein said spacing of said pinfeed holes is one-half inch, center-to-center, said length of said envelope blank section is 9 1/3 inches, and n is equal to
 3. 12. A continuous forms envelope converter for receiving a continuous paper strip having a pair of longitudinal lines of weakness spaced inwardly from the sides of said strip to provide side margins, a longitudinal row of pinfeed holes in each of said side margins, a plurality of successive integral full envelope blank sections, a first transverse line of weakness on each of said envelope blank sections extending from one side edge of the strip to the other side edge of the strip and constituting a first fold line between a bottom sheet portion and a top sheet portion of said envelope blank section, a second transverse line of weakness on each of said envelope blank sections extending from one of said longitudinal lines of weakness to the other of said longitudinal lines of weakness and constituting a second fold line between said top sheet portion and a closure flap portion of said envelope blank section, said closure flap portion having an edge corresponding to the leading edge of said envelope blank section contiguous with the trailing edge of an adjacent envelope blank section, the leading full envelope blank section having a leading edge contiguous with the trailing edge of a leading partial envelope blank section, said leading partial envelope blank section having a dimension longitudinally of the strip equal to the distance between the trailing edge of a full envelope blank section and said first fold line, said continuous strip being fan folded along said first fold line to form a zig-zag folded stack, said envelope converter comprising: intermittent feed means for engaging said rows of pinfeed holes in each side margin for feeding said strip from said zig-zag folded stack; die means for dieing out portions of said side margins adjacent said top sheet portion and said closure flap portion, the portions of said side margins adjacent said bottom sheet portion then constituting side flaps integral with said bottom sheet portion; means for separating said envelope blank sections from said strip at said trailing edge of said envelope blank sections; side flap fold means for folding said side flaps over said bottom sheet portion; means for folding said top sheet portion over said bottom sheet portion along said first fold line; means for adhesively securing said folded over side flaps to said top sheet portion; manual feed means for manually advancing said intermittent feed means to feed the leading edge of said strip into said envelope converter after engagement of said pinfeed holes with said intermittent feed means; and blocking means for diverting said leading partial envelope blank section to a waste receptacle after it is separated from said strip by said means for separating said envelope blank sections from said strip.
 13. A continuous forms envelope converter as recited in claim 12, wherein said blocking means comprises a member pivotable to a first position blocking movement of said envelope blank sections to said side fold means and pivotable to a second position permitting movement of said envelope blank sections to said side fold means.
 14. A continuous forms envelope converter for receiving a continuous paper strip having a pair of longitudinal lines of weakness spaced inwardly from the sides of said strip to provide side margins, a longitudinal row of pinfeed holes in each of said side margins, a plurality of successive integral envelope blank sections, each of said envelope blank sections being provided with a first transverse line of weakness extending from one side edge of said strip to the other side of the strip and constituting a first fold line between a bottom sheet portion and a top sheet portion of said envelope blank section, each of said envelope blank sections being provided with a second transverse line of weakness extending from one of said longitudinal lines of weakness to the other of said longitudinal lines of weakness and constituting a second fold line between said top sheet portion and a closure flap portion of said envelope blank section, said closure flap portion having an edge corresponding to the leading edge of said envelope blank section contiguous with the trailing edge of an adjacent envelope blank section, and adhesive coatings on said closure flap and adjacent to the side margins of said top sheet portion, said strip being fan folded to form a zig-zag folded stack, said converter comprising: a pair of intermittent feed means for engaging respectively said row of pinfeed holes in each side margin for feeding said strip from said zig-zag folded stack; a pair of die means for dieing out portions respectively of said side margins adjacent said top sheet portion and said closure flap portion, the portions of said side margins adjacent said bottom sheet portion then constituting side flaps integral with said bottom sheet portion; means for separating said envelope blank sections from said strip at said trailing edge of said envelope blank sections; a pair of side flap fold means for folding a respective side flap over said bottom sheet portion; first fold means for folding said top sheet portion over said bottom sheet portion along said first fold line to bring said folded over side flaps into engagement with the adhesive coatIngs on said top sheet portion, said first fold means including first guide means for receiving each of said envelope blank sections, means for conveying said blank sections into said guide means, leading edge first, first stop means on said first guide means for engaging said leading edge to cause said envelope blank sections to buckle along said first fold line, and first roller means for engaging said blank sections on opposite sides of said fold line for engaging said bottom sheet portion with said top sheet portion and for conveying said folded envelope blank sections in a downward path, folded edge first; a pair of heater means along said downward path for activating respectively the adhesive coatings on said top sheet portion to form completed envelopes; and second fold means for folding said closure flap portion over said bottom sheet portion, said second fold means including second guide means below said pair of heater means for receiving each of said completed envelopes conveyed along said downward path, folded edge first, from said pair of heater means, second stop means on said second guide means for engaging said folded edge to cause said completed envelopes to buckle along said second fold line, and second roller means for engaging said completed envelopes on opposite sides of said second fold line for engaging said closure flap portion with said bottom sheet portion and for conveying said completed envelopes along a horizontal path to discharge said completed envelopes from said converter. 